Door or related structure



Feb. 11, 1969 D. E. MOCK 3,426,482

DOOR OR RELATED STRUCTURE Filed Jan. 10, 1968 Sheet 012 v I 5 54' 40 Ma36 4a 1 32 54 22 44 2 45 v w\\\s w I 40 M/VEA/TOR 42 DONALD E MOCK 4 BYZ0 26 Z EDWARD D. O'BR/AA/ A TTOE/VEV Feb. 11, 1969 MQCK I 3,426,482

noon OR RELATED STRUCTURE Filed Jan. 10, 1968 Sheet 2 of 2 FIG. 2

IN l/EA/ 70R DONALD E. MOCK EDWARD D. OER/AN AWOE/VE) United StatesPatent 3,426,482 DUOR OR RELATED STRUCTURE Donald E. Mock, Covina,Calif., assignor to Anjac Plastics, Inc., El Monte, Calif. Filed Jan.10, 1968, Ser. No. 696,879 US. Cl. 49--501 Int. Cl. E0670 3/00, 3/72 4Claims ABSTRACT OF THE DISCLOSURE Background of the inventionTraditionally doors and related structures have been formed so as to berelatively heavy in character. Frequently they have been constructed soas to be solid structures out of wood, metal and the like. More recentlyit has been conventional to form doors and various similar structures byusing an edge frame and attaching this frame to whatever internalbracing may be required and then laminating or otherwise attachingexposed door surfaces to the frame. While structures of these andvarious other related categories are unquestionably satisfactory formany applications, they nevertheless are disadvantageous for others.

As an example of this in the recreational vehicle and aircraftindustries weight is a matter of primary importance. Conventional dooror related structures tend to be undesirably heavy for such uses. Inthese industries it is considered desirable and/or necessary to lowerthe weight of various items used to as great a degree as is reasonablypossible. However, in so doing care must be taken so as not todetrimentally affect the performance and/ or utility of an item. Thus,for example, a door or related structure for use in industries such asare indicated should be as light in weight as is reasonably possible,yet should be structurally sufiiciently strong so as to functionsatisfactorily in the intended manner.

A door or similar structure for use in the recreational vehicleindustry, in aircraft or in other related applications should not onlybe light in weight. Doors and similar structures for use in these fieldsshould be capable, of being easily and conveniently manufactured withless difliculty and at a lower cost than various conventional doorstructures as indicated in the preceding. Further they should be of sucha character as to present a neat, functional, yet attractive appearance.In the past it is considered that it has been difficult if notimpossible to combine all of these desirable features or characteristicsinto a single door or related structure of a conventional type.

Summary of the invention An object of the present invention is toprovide new and improved doors and related structures which overcomevarious disadvantages and limitations of more conventional relatedstructures such as are briefly indicated in the preceding. Anotherobject of this invention is to provide new and improved doors andrelated structures which are comparatively light in weight, which may beeasily and conveniently constructed at a comparatively nominal cost, andwhich are capable of satisfactorily performing their intended functions.A further, but closely ice relative objective of this invention is toprovide door and related structures which lend themselves to easy andcon venient factory manufacture using pre-finished panels.

-In accordance with this invention these and other related objectives ofthis invention are achieved by using structural members, each of whichhas a back wall, two outer walls attached to the edges of the back wallso as to extend from one side thereof in such a manner as to convergetowards one another and positioning means located on the back wallbetween the outer walls. Structural members of this type are used so asto frame a door in order to hold panels such. as pre-finished panelsbetween the outer walls and the positioning means. Because of theconstruction of the outer Walls and the manner in which they convergethe panels used are firmly and resiliently held so that the entire dooror related structure created is structurally adequate for an intendeduse, and yet presents a very neat appearance while retaining acomparatively light weight.

Description of the drawings The actual details of this invention arebest explained with reference to the accompanying drawings in which:

FIG. 1 is an isometric view showing a presently preferred embodiment orform of a door of this invention in use on a cabinet;

FIG. 2 is a partial cross-sectional view taken at line 2-2 of FIG. 1;

FIG. 3 is a partial isometric view of a structural member of thisinvention employed in the door in FIG. 1 showing the cross-sectionalconfiguration of this member;

FIG. 4 is an isometric view of a corner structural angle used with thestructural member shown in FIG. 3 in creating a door such as is shown inFIG. 1;

FIG. 5 is a partial cross-sectional view corresponding to FIG. 2 ofanother embodiment. or form of a door of this invention;

FIG. 6 is an isometric view of a corner structural angle used increating a door such as is shown in FIG. 5.

FIG. 7 is a partial cross-sectional view corresponding to FIG. 2 of afurther embodiment or form of a door of this invention; and

FIG. 8 is an isometric view of a corner structural angle used increating a door such as is shown in FIG. 7.

Description of the preferred embodiment In FIG. 1 of the drawing thereis shown a conventional cabinet 10 employing a door 12 of the presentinvention. This door utilizes four identically formed structural members14 connected together by means of structural angles 16 as are shown inFIG. 4. One of the structural members 14 is attached to the cabinet 10through the use of conventional hinges 18. These structural members 14are used so as to hold panels 20 of a fiat configuration. One of theadvantages of this invention lies in the fact that these panels 20 maybe pre-finished so as to have any desired type of appearance orconfiguration at the time they are manufactured prior to their assemblyinto the door 12..

The nature of the structural member 14 is considered a matter of primaryimportance with respect to this invention. Preferably the structuralmembers 14 are formed by known extrusion techniques out of a somewhatstiff, yet somewhat resilient polymer material such as rigid polyvinylchloride or ABS or the like. As formed each of these structural members14 has a generally flat back wall 22 having side edges 24. From each ofthese side edges 24 there extend on the same side of the wall 22 twoouter walls 26 which gradually converge towards one another. If desiredthese walls 26 may have tapered ends 28 primarily for .appearance typepurposes.

Between the walls 26 inner walls 30 extend from the back wall 22 so asto be perpendicular to these back walls.

These inner walls 30 preferably have grooved surfaces 31 and terminatein curved lips 32 extending towards one another. In the structuralmembers 14 the inner walls 30 are prevented from leaning or deformingtowards one another by a spacer wall 34 attached to the inner walls 30adjacent to the lips 32 in such a manner so as to extend between theinner walls 30 parallel to the back wall 22 so as to define an elongatedcavity 36. This assembly of the walls 30 and 34 can be considered apositioning means because of its function as hereinafter explained.U-shaped channels 38 are in effect defined by the outer walls 26, theback wall 22 and the inner walls 39. Because of the structure describedthese channels are larger at their bases along the back wall 22 than attheir open ends between the edges 24 and the curved lips 32.

The structural members 14 preferably also include a trim lip 40 which isintegral with the back wall 22 on the side thereof remote from the walls26 and 30. The particular trim lip 40 shown has a curved normallyexposed wall 42 leading to an abutting wall 44 which extends roughlyperpendicular to the back wall 22. This abutting wall 44 preferably isprovided with an offset 46 adjacent to the back wall 22 so that only asmall area of the abutting wall 44 will touch and contact the cabinetaround the complete door 12 and a retainer bead 45. This lip 40 ineffect defines an enclosed channel.

The structural angles 16 used with the door 12 in order to connect thestructural members 14 are shown in FIG. 2 of the drawing. These angles16 may conveniently be made of metal or other rigid material and areattaching members. Each of these angles 16 has two elongated back legsor walls 48, adjacent edges 49 of which are joined at a right angle.

In assembling the door 12 the ends of the structural members 14- aremitred in the conventional manner. Next all except one of the structuralmembers 14 in the door 12 may be connected by inserting angles 16 withinthe interiors of the lips 40 of these structural members 14 so that theback walls 48 fit closely against the walls 44 adjacent the walls 22 andso that the walls 52 lie against the walls 22 so as to resiliently andrigidly engage these walls and hold the structural members 14 at a rightangle with respect to one another. If desired a conventional adhesivemay be applied to the surfaces of the angles 16 which contact thesewalls so as to seemly hold them in place.

Then the panels 20 may be slipped into place within the channels 38 bycausing a slight deformation of the outer walls 26. The curved lips 32are considered to facilitate this operation. As a result of thisdeformation the outer walls '26 will firmly and resiliently engage thepanels 20 so as to create a unitary structure. If desired, a smallquantity of adhesive may be inserted in the channels so as to hold thepanels 20 in place even more securely. If an adhesive is used here thegrooves 31 aid in achieving the intended holding action. If the adhesivewill only bond to the panels 20 because of the material used in themembers 1 4 such adhesive will tend to form a mechanical interlock withthe grooves 31. Then after these operations are completed the remainingstructural members 14 will be attached using two more of the structuralangles 16 in the general manner indicated.

As a result of this sequence of operations it is possible to create astructural door such as the door 12 in which the structural members 14serve .as a frame, this door having sufiicient rigidity and structuralstrength for normal satisfactory use in vehicles such as trailers,campers, aircraft or the like. In such uses a door such as the door 12is considered to be particularly advantageous because of its lightweight. Such doors are also particularly desirable inasmuch as they canbe easily and conveniently assembled using pre-finished panels as thepanels 20 so as to have any desired decor or appearance.

One item of particular significance with respect to the door 12 is themanner in which. the Structural angles 16 are used. It is possible toconnect the structural members 14 by using structural anglescorresponding to the angle 16 which fit within the cavity 36. Structuresof this type are utilitarian in nature. However, with them there may bea problem in getting the end edges of the mitred corners to fit closelyenough so as to have a desired appearance. With the door 12 thisdifficulty is eliminated because the structural angles 16 are located asclosely adjacent to the extreme ends of the mitred corners as isconveniently possible and are tightly held in place by fitting againstadjacent parts. It is considered significant that structural angles suchas the angles 16 located in this location adequately connect thestructural members 14 so that the ends of the mitred corners of thesemembers are adequately held in order to accomplish applicants purposes.

In FIG. 5 of the drawing there is shown a modified door 50 of thepresent invention. This door 50 uses parts which are identical to partsof the door 12 previously described. For this reason various parts ofthe door 50 which are the same as parts of the door 12 are notseparately identified herein, and when necessary for descriptive andillustrative purposes are described by the primes of the numeralspreviously used.

In the door 50 the structural angles 16 are replaced by much simplerstructural angles 52 each consisting of a bent piece of metal havingpointed legs 54 joined together at a right angle. These structuralangles 52 are designed to be used in the same manner as the structuralangles 16. When employed they fit against the beads 45 so as to abutagainst the back walls 22 and the abutting walls 44. Preferably thestructural angles 52 are dimensioned so as to fit tightly within theselocations. The structural angles 52 are not considered to be assatisfactory as the structural angles 16 since because of the nature oftheir construction they cannot resiliently engage the parts contacted bythem so as to achieve a resilient holding action.

In FIG. 7 of the drawing there is shown a modified door 60 of thepresent invention. This door 60 also uses parts which are identical toparts of the door 12 previously described. In the interest of brevitythe various parts of the door 60 which are the same as parts of the door12 are not separately described or identified herein. When necessary fordescriptive and/or illustrative purposes these parts which are the sameare indicated by the double primes of the numerals previously used.

In the door 60 the structure angles 16 are replaced by differentstructural angles 62, each consisting of a fiat metal base 64 in anL-like shape having legs 65 equal length. The outer edges of this base64 carry a turned up lip 66 having a rounded corner 78. The inner edgesof this base 64 carry right angle walls 70 which preferably are providedwith sloping ends 72. A sloping corner 74 may be provided at each of theends of the base 64.

The structure of this structural angle 62 is designed so that an angle62 may be inserted in a structural number 14" as shown in FIG. 7 withthe base 64 fitting against the wall 44" and with the lip 66 reaching upso as to engage in a press fit manner the wall 42". In this position awall 70 fits against the back wall 22 so as to extend between the walls42 and 44- in a press fit type of engagement, firmly holding the anglemember 62 in place. The sloping end 72 and the corner 74 aid in theinsertion of the angle member 62 in the desired position.

It will be realized that the doors 12, 50 and 60 can be classified asstructurally stable members resistant to sagging and the like by virtueof the manner in which panels are held within them. This makes thestructures described sufficiently strong to be used as doors or the likefor structural purposes even when comparatively thin and weak panels areemployed. Although it is not considered desirable or necessary forspecialized purposes it is possible to fill the space between the panels20 in the doors 12 and 50 with a nonstructural insulating or soundabsorbing material.

I claim:

1. A door structure which comprises:

a plurality of structural members;

each of said structural members including a back wall panel holdingmeans located on one side of said back wall so as to extend outwardlytherefrom and trim means located on the other side of said back wall soas to extend outwardly therefrom;

each of said structural members having mitered ends;

each of said trim means including an abutting wall exa back wall havingopposite sides and longitudinal side edges;

panel holding means attached to one of said sides so as to extendtherefrom;

said panel holding means including two outer walls attached to the sideedges of said back wall so as to extend therefrom;

said outer walls converging towards one another prior to the use of saidstructural members and being capable of being deflected outwardly bycontact with tending perpendicular to said back wall and other 10 thepanel means during the use of said structural wall means extending fromthe extremity of said abutmember;

tin-g wall to said back wall, said abutting wall and positioning meanscarried on said back wall between said other wall means defining ahollow section besaid outer walls;

tween the longitudinal edges of Said back Wall; said positioning meansincluding two inner walls spaced said structural members being locatedwith respect to from said outer walls and from one another and oneanother in a position defining a frame so that the extending away fromsaid back wall and a spacer mitered ends of said structural members fitagainst all extending between said inner walls;

one another with the hollow interiors of said trim said positioningmeans including curved lips forming means being in communication withone another and extensions of said inner walls on the extremities ofwith said panel holding means being adjacent to one said inner wallsremote from said back wall;

another; said lips being curved towards one another so as to rigidstructural angle means located at the adjacent be adapted to facilitatethe introduction of panel ends of said structural members, each of saidangl means between said inner walls and said outer walls;

means having two leg means, each of said leg means hollow trim meansattached to the other of said sides extending into the hollow interiorof one of said trim of said back wall adjacent one edge thereof so asmeans so as to fit against the interior thereof, said to extendtherefrom;

structural angle means holding said structural memsaid hollow trim meanshaving an interior shaped so bers in position with respect to oneanother; as to receive and hold a rigid member used in joinretainermeans formed integrally with each of said trim 3O ing two adjacent ofsaid structural members together means within the interior thereof, saidretainer means at a right angle;

engaging said structural means so as to position said said trim meansincluding an abutting wall extending structural angle means within saidhollow trim means; per endi ularly to aid back wall and other wall andmeans extending from the extremity of said abutting panel means held bysaid panel h g means n each wall to said back wall, said abutting walland said of said structural members so as to extend across the ther wallmean defining a hollow section between interior of the frame defined bysaid structural memthe longitudinal edges of said back wall.

bers. 4. A structural member as claimed in claim 3 wherein: 2. A doorstructure as claimed in claim 1 wherein: said abutting wall is providedwith an offset adjacent each of said panel holding means comprises: tosaid back wall, said offset providing a portion of two outer wallsattached to edges of said back walls aid abutting all remot fro said bak w ll exso as to extend therefrom; tending outwardly from the remainderof said abutpositioning means carried on said back Wall between tingwall.

said outer walls; References Cited said positioning means and said outerwalls defining UNITED STATES PATENTS continuous spaced channels openingaway from said back Wall; 2,776,735 1/1957 Bancroft 2.87189.36 saidouter walls prior to the assembly of said door 2,909,814 10/1959Schwartz 52309 structure converged towards one another; 0 3,363,390 1/1968 Crane et al 52-627 said positioning means have curved lipsextending out- 0 wardly therefrom, said lips being adapted to facili-FOREIGN PATENTS tate the introduction of said panel means into said606,418 10/1960 Canadachannels, said panel means deforming said outerwall 1,371,645 7/ 1964 Francemeans outwardly upon the introduction ofsaid panel means into said channels; and 55 KENNETH DOWNEY, PrimaryExaminer.

said panel means comprising a panel in each of said continuous spacedchannels.

U.S. Cl. X.R.

3. A structural member for use in forming a door 49-401; 52616, 627, 656structure, which structural member comprises:

